I managed to get the cases back together, The silencer changed to a 1.25" core, and a new outlet in the head.

Hi.i m doing a cr500 ktm project too. 94 engine with a sxf 450 2008 frame. It s welded painted put together almost completly. I m waiting for the air boot and griphics. I notice that the cdi u r using ( the part attached to the frame and connected to the spark plug) is not the original one and fit perfect on the frame mount. Where does it come from? Also my brake pedal is a little too close from the case, did u have to bend it too? I really like ur blog it help me a lot on my builng. I should have it running next week end. My engine was nothing like urs, just did top end. I also have different radiators, from a xc i think, so i ll run some different hose and use the two holes on the head. I didnt have to mod much the pipe and silenceur either. Lucky on that one. Thx